DIRECT DRIVE SERVOVALVE HAVING MOTOR POSITION SENSOR

Abstract: A direct drive servovalve which includes as an integral part thereof, a motor rotor position sensor (46). The rotor position sensor (46) is used to generate an electrical signal which is representative of the degree of rotation of the rotor (52) from its null position. This signal is utilized in the feed back loop to accomplish control of the drive motor (18). The sensor (46) may include a HALL effect device (74) which is activated by the permanent magnets (70) utilized as a part of the rotor (52) of the drive motor or alternatively by a separate permanent magnet (78) which is mounted upon the rotor shaft (68) of the drive motor rotor (52). Alternatively, the position sensor (46) may include a potentiometer (80) which is mounted internal of the drive motor (18).

Description: DIRECT DRIVE SERVO VALVE HAVING MOTOR POSITION SENSOR Field of the Invention This invention relates generally to direct drive servo valves and more particularly to a direct drive servo valve in which the motor rotor position is sensed to generate an electrical signal representative of that position. Background of the Invention Torque motor driven spool valves are well known in the art including those which operate through the utilization of a rotary torque motor having a drive member extending from the rotor thereof into contact with the spool valve to directly reciprocate the spool valve within a bore provided in the valve housing to thereby control the flow of fluid from a source thereof to the load in response to electrical signals applied to the drive motor. Typical of such direct drive servo valves is that illustrated in U.S. Patent No. 4,793,377 issued December 27, 1988 to Larry E. Haynes et al. The invention described and claimed herein is an improvement over the direct drive servo valve disclosed in U.S. Patent No. 4,793,377 and therefore the disclosure of SBBSi U.S. Patent No. 4,793,377 is incorporated herein by this reference. Other prior art known to applicant is U.S. Patent Nos. 4,197,474; 2,769,943; 2,697,016; 4,452,423; 4,339,737; and, 4,702,123 as well as Canadian Patent 601808 issued July 19, 1960 and United Kingdom Patent 1521668 issued August 16, 1978. It is often a requirement in such prior art servo valves to have position feed back for utilization in closing a servo loop to cause the valve to operate properly under the conditions of the particular application. In the prior art, such position feed back is typically generated through the utilization of a linear variable differential transformer (LVDT) which is coupled to the spool valve to provide spool position feed back. Such LVDT's are extremely expensive and thus add to the cost of the valve significantly. In addition to the high cost of the LVDT special provisions generally are made to operate the LVDT "wet" in a hydraulic chamber in order to eliminate sealing and friction concerns. In addition, the method of connection of the LVDT to the spool is very critical and such a valve utilizing an LVDT is difficult to adjust at null and also requires complex electronics to properly process the input and output signals of the LVDT. The control loop closure in a typical servo system involves motor command and spool position feed back. Any looseness between the motor and spool connection results in servo valve instability. Summary of the Invention In accordance with the present invention, there is provided a force motor for use with a hydraulic control system which includes a rotor having a shaft carrying a permanent magnet means and being supported by bearing means. Positioned about the rotor is a stator SUBSUME SHEET (BULE 26) comprised of magnetically permeable laminates with the usual field windings disposed thereon. The rotor of the motor is designed and restricted so that it moves only through a limited angular motion less than 360°. Position sensor means is carried by the motor and produces an electrical signal representative of the rotary angular position of the rotor of the torque motor. In accordance with a more specific aspect of the present invention, the position sensor comprises an analog HALL effect device positioned to sense the moving magnetic field associated with the position of the rotor. The moving magnetic field may be that generated by the permanent magnet means carried by the rotor shaft and used in conjunction with the normal operation of the motor. Alternatively, there may be provided a separate permanent magnet disposed upon the rotor shaft properly aligned with the permanent magnet means of the motor rotor and positioned adjacent the HALL effect device. As a further specific aspect of the present invention the motor positioning sensor may be a potentiometer, typically of the non-wire wound type, mounted adjacent the motor rotor in such a manner that the wiper of the potentiometer is carried by the rotor shaft thereby developing a rotor position signal as the wiper is caused to angularly move as the motor rotor moves responsive to the input signals applied to the motor. Brief Description of the Drawings Fig. 1 is a schematic representation in cross section illustrative of a limited angle direct drive servo valve constructed in accordance with the principles of the present invention; SϋBSTΪΪϋlt Fig. 2 is a schematic representation showing a HALL effect device positioned adjacent permanent magnets for producing a position signal in accordance with the principles of the present invention; Fig. 3 is a graph illustrating the output signal from a structure such as that illustrated in Fig. 2; Fig. 4 is a schematic illustration of a limited angle rotary torque motor showing the position of a HALL effect sensor activated by the permanent magnet means carried by the rotor and normally used in the operation of the motor; Fig. 5 is a schematic illustration similar to that of Fig. 4 but wherein a separate permanent magnet other than that used in the normal operation of the servo motor is used to activate the HALL effect device; Fig. 6 is a schematic illustration of a limited angle rotary torque motor utilizing a potentiometer wherein the resistance element is disposed upon the top of the motor housing; Fig. 7 is a fragmentary view similar to that of Fig. 6 but with the resistance element of the potentiometer disposed upon the side wall of the motor housing; Fig. 8 is a graph illustrating the output from a potentiometer position sensor wherein the output electrical signal is linear; Fig. 9 is a graph illustrating the output electrical signal of a position sensor wherein the electrical output signal is shaped according to a predetermined function; Fig. 10 is an illustration showing a limited angle torque motor constructed in accordance with the principles of the present invention; and Fig. 11 is a top view of a portion of the torque motor of Fig. 10 taken about the lines 11-11 thereof. Description of the Illustrative Embodiments By referring now more particularly to Fig. 1 there is schematically illustrated a limited angle rotary to linear direct drive servo valve constructed in accordance with the principles of the present invention. As is therein shown, there is provided a housing 10 within which there is disposed a spool valve 12 for reciprocal movement responsive to angular displacement of a drive member 14 extending from the shaft 16 of the torque motor 18. As is well known to those skilled in the art and as illustrated in the prior art above referred to, the drive member 14 is eccentrically positioned on the shaft 16 so that as the shaft 16 rotates about its center line 20 the drive member 14 moves in such a way as to impart reciprocal movement to the spool valve 12. Such movement causes fluid under pressure which is applied to a port 22 and appears at opposite ends 24 and 26 of the spool valve 12 to be controlled. If the spool valve 12 moves to the right as viewed in Fig. 1, the fluid under pressure flows to a load (not shown) through the port 28 and alternatively, if the spool valve 12 moves to the left then the flow of fluid is through the port 30 to the load. In either case, the return flow is through the port 32. As is well known to those skilled in the art, the torque motor 18 includes a permanent magnet 34 carried by the shaft 20 and disposed within and surrounded by field windings 36 carried upon an appropriate magnetically permeable core or laminate stack. The shaft 16 is supported by bearings 38 and 40 at opposite ends thereof. Under some applications, an SUBSTTTUTE SHEET (RULE 26) appropriate seal 42 may be provided to isolate the fluid under pressure from the motor. As is shown in Fig. 1 the shaft 16 has an extension 44 at the upper end thereof. Disposed adjacent this extension 44 is a position sensing means 46. The position sensing means 46 produces an output electrical signal which is proportional to the rotary angular position of the rotor of the torque motor 18. As above indicated, the position sensing means may take any form known to those skilled in the art which will provide an output electrical signal proportional to such angular rotary position. One preferred form of the angular position sensing means 46 is illustrated in Fig. 2 to which reference is hereby made. As is therein shown a permanent magnet 50 is carried on a shaft 52 and has four poles oriented thereabout and polarized alternatively as shown. Positioned adjacent the magnet is a HALL effect device 54 which has an electrical signal applied thereto and provides an output signal therefrom by way of the electrical leads shown at 56. It is well known to those skilled in the art that as the rotor 52 rotates through a 180° rotational cycle an output signal such as that shown in Fig. 3 is generated. In Fig. 3 spool position is shown on the abscissa and output voltage is shown on the ordinate. Thus, if the rotor 52 were permitted to rotate continuously a sine wave, much as that shown in Fig. 3, would be continuously generated. However, it will be remembered that the direct drive servo valve which is the subject matter of the present invention is a limited angle direct drive servo valve. That is, the rotor of the servo valve is limited in its rotation to a specified number of degrees less than 360°. For example, for the four pole apparatus as shown in Fig. 2, the limited angular rotation permitted would be in the order of + 25° as is shown by the dashed lines 58 and 60 of Fig. 3. It will also be noted by those skilled in the art that the electrical output signal generated by the HALL effect device 54 is substantially linear over the range between + 25°. If a two pole motor is utilized then the substantially linear operating range thereof would be extended to approximately ± 50°. It will be recognized by those skilled in the art that the use of HALL effect devices as electrical sensors for commutation of rotating motors is well known. Such HALL effect devices are used as digital switches to sequentially switch coil winding current on and off at the appropriate time to provide torque for smooth motor rotation. Examples of such prior devices are illustrated in U.S. Patents 4,494,028 and 4,311,933. In each of these patents as well as others well known to those skilled in the prior art, the HALL effect devices are used as part of the commutation device for brushless direct current motors. In accordance with the present invention, the HALL effect device does not function as part of a commutation system but rather as above pointed out, is used to generate an electrical signal which is proportional to the precise positioning of the rotor within a limited angle as opposed to an on/off switched voltage which is typical in the prior art motors. By reference to Fig. 4 there is illustrated one embodiment of a limited angle direct drive torque motor constructed in accordance with the principles of the present invention and utilizing a HALL effect device as a position sensor. The embodiment as illustrated in Fig. 4 includes a motor housing 62 within which there is positioned a stator 64 and a rotor 66. The rotor 66 includes a shaft 68 upon which there is disposed permanent magnet means 70. As is shown in Fig. 4 the SUBSimiTE SHEET (RULE 26) permanent magnet means extends above the magnetically permeable core material 72 by an amount illustrated as "d" . This provides an extension of the rotor carried permanent magnet means into the upper portion of the housing 62. Such extension causes the magnetic field generated by the permanent magnet means 70 to extend beyond the magnetically permeable core member 64 and into contact with a HALL effect device 74 which is positioned on the interior surface of the housing 62. The positioning of the HALL effect device 74 is such that the highest possible signal to noise ratio is generated when the permanent magnet means 70 rotates. To accomplish this, the HALL effect device 74 is positioned radially outwardly and/or longitudinally with respect to the permanent magnet means 70 as to just avoid magnetic saturation of the HALL effect device 74. Such adjustment may be accomplished by inserting material between the HALL effect device 74 and the inside surface of the housing 62 to bring the HALL effect device 74 closer to the permanent magnet means 70 or by shifting the HALL effect device 74 vertically up or down as viewed in Fig. 4 to accomplish the desired signal to noise ratio of the output signal from the HALL effect device. The HALL effect device may also be mounted upon the laminate stack of the stator if such a position provides the desirable signal to noise ratio. Referring now more specifically to Fig. 5, there is illustrated a limited angle torque motor similar to that shown in Fig. 4 except that the permanent magnet means 76 carried on the shaft has been reduced in size to the standard size normally utilized in such torque motors as known to those skilled in the art. As is clearly evident from the illustration of Fig. 5, instead of extending the permanent magnet 66 as illustrated in Fig. 4, there is provided a separate and independent permanent magnet 78 which is affixed to the shaft 68 and rotates therewith. The added permanent magnet 78 must be properly oriented with regard to the permanent magnet means 76 so as to provide the desired rotor position with respect to the hydraulic null position of the servo valve as illustrated in Fig. 1 to which the motor is affixed. Again the HALL effect device 74 must be positioned as above described in order to provide a signal having the highest signal to noise ratio possible and thus the positioning is done so that magnetic saturation is just avoided. If such is desired, the magnetization of the magnet 78 may be accomplished in such a way as to provide a tailored magnetic field thereby providing an output signal between the operating positions which is other than substantially linear. For example, the permanent magnet 78 may be magnetized in such a way as to provide a tailored output signal along the lines of that shown in Fig. 9. That is at approximately ± 15° of motor angular position from null the output signal from the HALL effect device is substantially linear and has a relatively shallow slope. However, between 15° and 30° on each side of null the slope increases and the signal is other than linear as is illustrated. This output signal may then be incorporated with other signal information and processed to provide appropriate feed back signals to the field windings to accomplish a desired positional relationship of the spool valve 12 in response to applied command signals. It will be appreciated by those skilled in the art that limited angle rotary direct drive torque motors of the type shown in Figs . 4 and 5 are constructed in such a manner that the rotor positioning sensor is integrated into the motor housing and thus no additional structure is required on the valve as would be the case with a linear variable differential transformer (LVDT) . It should further be recognized that the structures as shown in Figs. 4 and 5 may be operated either wet or dry and, since there is no direct physical contact between the rotor and the HALL effect sensor, there is no contamination or wear and thus a long position sensor life time results. Of the alternative embodiments shown in Figs. 4 and 5 the least expensive to manufacture is that shown in Fig. 4 sense the only additional element added to provide the rotor position sensing is the HALL effect device. Referring now to Fig. 6 there is illustrated a rotor position sensor which is constructed utilizing a potentiometer including a resistance element 80 affixed to the inner surface of the top of the housing 62 and a wiper means 82 which is affixed to the rotary shaft 68. The wiper means 82 includes a wiper arm 84 which carries the wiper contacts 86 which engage the inner surface of the resistance element 80. As the rotary shaft 68 is caused to rotate in response to electrical signals applied to the stator 64 the wiper contacts 86 move along the surface of the resistance element 80 and provide an output electrical signal which is proportional to the position of the motor rotor. By reference to Fig. 7, there is shown an alternative embodiment to that shown in Fig. 6 in which the resistance element 88 is affixed to the inner surface of the side wall of the housing 62 as opposed to the top surface thereof as is shown in Fig. 6. Under these circumstances the wiper means 90 includes a wiper arm 92 carried by the rotary shaft 68 with the wiper contacts 94 extending therefrom into engagement with the surface of the resistance element 88. The output electrical signal provided by the potentiometer construction as shown in Figs. 6 and 7 may be linear as shown in Fig. 8 or alternatively may be shaped as shown in Fig. 9 depending upon the particular application which is to be provided. It should be understood by those skilled in the art that the limited angle torque motors utilized for direct drive servo valves and constructed in accordance with the present invention may take any form desired depending upon the particular application. One specific embodiment of such a motor is illustrated in Figs. 10 and 11 to which reference is hereby made. As is therein shown, the motor 100 includes a housing 102 within which there is positioned a stator 104 which is held in place within the housing 102 by an anti-rotation pin 106. The motor is positioned upon a valve housing 108 (partially shown) . A rotor 110 is supported upon bearings 112 and 114 and carries permanent magnet means 116 as is well known to those skilled in the art. The bearing 114 is positioned within a bearing housing 118 and the rotor assembly is positioned and held in place to avoid back lash by an appropriate wave spring and shims 120 which urge the assembly downwardly toward the bearing 112. A separate permanent magnet 122 is carried upon an extension 115 of the shaft 110. As is shown in Fig. 11 a HALL effect device 124 is held in place upon a bracket 126. An appropriate cover 128 is provided and the bracket and cover are secured with appropriate fasteners 130. A retainer ring 132 is disposed upon the shaft extension 115 to restrain any longitudinal movement of the permanent magnet 122. Appropriate wiring 134 is used for conducting signals to and from the motor and the sensor. A cover 136 is utilized over the motor and an appropriate housing for electrical apparatus 138 is secured to the top of the cover. Appropriate packing or O-rings such as shown at 140, 193 and 142 are utilized to seal the motor housing. An eccentrically disposed drive pin 144 extends from the shaft 110 and is utilized to engage a spool valve and move the same reciprocally as above described in conjunction with Fig. 1. There has thus been disclosed a limited angle torque motor for utilization with a direct drive servo valve which incorporates as an integral part thereof a motor rotor angular position sensing apparatus including either a HALL effect device or a potentiometer.

Claims: WHAT IS CLAIMED IS: 1. A limited angle force motor comprising: a. motor means including a stator and a rotor, b. said rotor including a shaft, c. a housing enclosing said motor means, d. a rotor position sensing means disposed within said housing for producing an electrical signal proportional to the position said rotor deviates from null position. 2. A force motor as defined in claim 1 wherein said sensor means includes a HALL effect device. 3. A force motor as defined in claim 1 wherein said sensor means includes a potentiometer. 4. A force motor as defined in claim 2 wherein said rotor includes permanent magnet means affixed to said shaft for providing a magnetic field for activating said HALL effect device. 5. A force motor as defined in claim 4 wherein said permanent magnet means is an extension of rotor permanent magnet means used as a portion of said motor means. 6. A force motor as defined in claim 4 wherein said permanent magnet means is a separate permanent magnet carried by said shaft with said HALL effect device disposed adjacent thereto. 7. A force motor as defined in claim 5 wherein said HALL effect device is carried by said housing. 13 SUBSTITUTE SBST (RULE 26) 8. A force motor as defined in claim 6 wherein said HALL effect device is carried by said housing. 9. A force motor as defined in claim 5 wherein said HALL effect device is mounted upon said stator means. 10. A force motor as defined in claim 6 wherein said HALL effect device is mounted upon said stator means. 11. A force motor as defined in claim 3 wherein said potentiometer includes a resistance element and a wiper means, said resistance element being carried by said housing and said wiper means being carried by said rotor shaft. 12. A force motor as defined in claim 11 wherein said resistance element is secured to the inside top surface of said motor housing. 13. A force motor as defined in claim 11 wherein said resistance element is carried by the inner surface of a side wall of said housing. 14. A force motor as defined in claim 4 wherein said permanent magnet means is magnetized to provide a predetermined non-linear output signal from said HALL effect device over the operational portion of said output signal. 15. A force motor as defined in claim 11 wherein said resistance element is shaped to provide a predetermined non-linear output signal representative of rotor position.

Inventors: ELROD ALVON C JR, MUTHS DONALD A, NICHOLS LARRY L, SMITH ROBERT W, ELROD, ALVON, C., JR., MUTHS, DONALD, A., NICHOLS, LARRY, L., SMITH, ROBERT, W.
Applicants: HR TEXTRON INC, HR TEXTRON INC.
Application year: 1994
Main classification: G05D16
IPC codes: F15B9, F16K31, G05D16